Method and machine for the production of low emission biomass fuel composition from waste materials

ABSTRACT

The present disclosure provides a novel method and machine for the production of a biomass composition from waste materials including the steps of evaluating the waste material for emissions related factors, treating the evaluated waste material with the additive composition to form a low emissions biomass composition and shaping the biomass composition into solid fuel formations. The present invention further provides an additive composition used in the treatment of the waste materials that comprises an emission sponge, a filler and optional BTU modifier. The treating step includes the steps of sizing selected waste materials, blending the sized waste materials with the additive composition formulated specifically for the waste material and forming with a press the blended waste materials into solid fuel formations. The resulting biomass solid fuel formations produce lower emissions than typically produced by coal and may be combined with, or used in place of coal in fuel burning structures and devices.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Ser. No. 14/489,446 filed onSep. 17, 2014 which is a continuation in part of U.S. patent applicationSer. No. 14/217,153 filed on Mar. 17, 2014, which claims priority toprovisional applications U.S. 61/801,618 and U.S. 61/801,693, both filedon Mar. 15, 2013. All of these applications are herein incorporated byreference.

SUMMARY OF THE INVENTION

The present disclosure is related to machines and methods of convertingwaste materials into burnable fuel. More specifically, the presentdisclosure is directed to a machine and method of making a low emissionbiomass fuel composition from treated waste material.

The present disclosure is directed to a novel machine and method for theproduction of a biomass composition from waste materials, such aslandfill waste, industrial waste, construction waste, municipal garbage,biowaste including, but not limited to, switch grass, forest litter,paper waste, peat, cane waste, and other compostable garbage. The methodincludes the steps of evaluating the waste material for emissionsrelated factors, treating and processing the evaluated waste materialwith a machine to form a low emissions biomass composition and shapingthe biomass composition into solid fuel structures.

A machine is used to treat and process the waste material including thesteps of sizing selected waste materials, blending the sized wastematerials with an additive formulated specifically for the wastematerial and forming the blended waste materials into biomass fuelformations. The resulting biomass formations produce lower emissionsthan typically produced by coal and may be used as a replacement forcoal, or as an additive to be combined with coal, in coal burningstructures and devices.

Other features and advantages of the present invention will becomeapparent after study of the specification and claims that follow. Allpublications and patents mentioned in this application are hereinincorporated by reference for any purpose.

BRIEF DESCRIPTION OF THE DRAWINGS

The following disclosure can be better understood with reference to thefollowing detailed description together with the appended illustrativedrawing in which like elements are numbered the same:

FIG. 1A is a flow chart illustrating the steps involved in the processof making a low emission biomass composition.

FIG. 1B is a flow chart illustrating the steps for the treatment ofwaste materials within the process of making low emission biomasscomposition.

FIG. 2 is a flow chart illustrating the steps and mechanisms involved inthe process of making low emission solid fuel formations in more detail.

DEFINITIONS

As used herein, “waste material” and “waste materials” are defined asany waste materials, such as landfill waste, industrial waste,construction waste, municipal garbage, biowaste including switch grass,forest litter, paper waste, peat, cane waste, and other compostablegarbage.

As used herein, “emission” or “emissions” are defined as environmentallyundesirable gas byproducts of combustion, including greenhouse gases,carbon gases, and actually and potentially toxic or environmentallydetrimental gases.

As used herein, “emission sponge” is defined as a material that absorbstoxic emissions and spent fuel and re-burns the spent fuel resulting inreduced carbon emissions and reduced actual and potential toxic orenvironmentally negative emissions from the fuel. Emission spongesinclude, but are not limited to, salt, sea salt, baking powder, calciumfrom sea shells, rice, rice by-product, their equivalents, andcombinations thereof. The emission sponge is preferably salt, sea saltor combinations thereof.

As used herein, “filler” is defined as a material that acts as amechanical bond within the waste material to fill voids. Fillers includenatural products that would provide a mechanical bond between the wastematerial particles. These materials include flour, such as, soy flour,wheat flour, and rice flour, rice, oats, potatoes, their equivalents andcombinations thereof.

As used herein, “BTU modifier” is defined as a material that can hold ortransfer heat. BTU modifiers include, but are not limited to, steelslag, coal fines, iron powder, their equivalents, and, combinationsthereof.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides a novel method for the production of abiomass fuel composition from waste materials. The raw input wastetypically is municipal waste material that has been somewhatpre-processed before final disposal. Magnets may be used to help preventundesired metal from entering the machine. Again, typically presortingis minimal because waste is commonly presorted prior to final disposal.

Once it is determined that the waste is generally acceptable, the wasteis evaluated for emissions related factors and burn characteristics.This evaluation informs the machine operator as to the appropriatequantities of additive and the how to set various settings on themachine.

Referring to FIG. 1A, the method for the production of a biomass fuelcomposition from waste materials includes the steps of evaluating (10)selected waste material for emissions related factors, treating (20) theevaluated waste material to adjust the emission levels of the biomasscomposition, and forming (30) the biomass composition into solid fuelformations. The solid fuel formations resulting from this method willtypically produce lower gas emission than coal alone. The solid fuelformations may be used in place of, or combined with coal, in fuelburning structures and devices.

In the evaluation step (10) information regarding certain properties ofa selected starting waste material is gathered. These properties includethe moisture/water content of the waste material, the gas emissionlevels released by the untreated waste material when it is burned, andthe BTU levels produced by the untreated waste material when it isburned. The emission levels and BTU levels are then compared to thepredetermined target levels for each property and used to formulate anadditive used to produce a biomass fuel composition that displays targetproperties.

The moisture/water content of the untreated waste material will varygreatly but is preferably between 12.0% and 25.0% by weight and mostpreferably between 18.0% and 23.0% by weight. If the water content ofthe waste material needs to be increased, water will be added to thewaste material during the treatment stage. If the water content isdetermined to be too high, additional waste material may be added toreduce the percentage of water in the waste material. Alternatively, thewaste material may be dried until the water content is within theacceptable range.

The gas emission level of the untreated waste material is adjusted toits target level through the addition of an additive during thetreatment step. The additive package may include an emission sponge, afiller and an optional BTU modifier. The formulation of a specificadditive is determined by modifying batches of the untreated wastematerial with emission sponge, filler and optionally, BTU modifier untilthe target levels are achieved. For example, if the waste material ismunicipal garbage and it produces emissions higher than desired, thespecific amount of emission sponge needed to lower the gas emission tothe target level is calculated and included in the additive compositionformulated for the municipal garbage. Likewise, if a BTU rating of amunicipal garage sample is less than a desired amount, a BTU modifier isincluded in the additive to adjust the BTU rating of the municipalwaste. The amount of BTU modifier needed to increase the BTU rating ofthe garbage is calculated and included in the additive compositionformulated for the municipal garbage.

Although the particular formulation of the factors in the additivecomposition will vary depending upon specific target requirements, theamount of emission sponge is preferably between 0.1% to 10.0% by weight,and most preferably between 1.5% to 3.0% by weight, and, the amount offiller is preferably between 0.1% to 6.0% by weight, and most preferablybetween 1.0% to 3.0% by weight. If the biomass fuel composition will beused as an additive to be combined with coal, a BTU modifier will not beneeded in the additive because the coal will serve as a BTU modifier. Inthis circumstance, the amount of emission sponge included in theadditive composition, may be overloaded to provide emission reductionfor the waste material and the coal with which it will be blended. Ifthe biomass fuel composition is not being used as an additive, theamount of BTU modifier present in the additive is preferably between0.1% to 50.00% by weight, and most preferably between 3.0% to 5.0% byweight.

Referring to FIG. 1B, the treating step (20) further comprises sizereduction (22) of the selected waste materials soaking and blending (24)the sized waste materials with the additive composition formulatedspecifically for the waste material. An additional second size reduction(26) step may be necessary depending on the particle size of the biomasscomposition.

Referring to FIG. 2, after the evaluation step, the waste material mustbe sized (120) to ensure the diameter of the waste material particlesare uniform and not greater than one half inch. If the waste materialparticles have been pre-sized to fall within these parameters, a firstsize reduction is not needed. If, however, the waste material isirregular in shape and includes particles greater than one half inch indiameter, the particles are introduced to a hopper (100). Typically, afront-end-loader places the waste material into the hopper. The hopperhas a means, such as gates, meters or sized openings to control the flowof the waste material onto a conveyor belt or similar physical conveyor.In alternative embodiments, multiple hoppers may be used to allow forthe automatic and independent control of waste materials and additivesentering the machine. In such an embodiment, each hopper is controlledvia gates, meters, or openings to control the ratio of each hopper'scontent in the blend. In yet another alternative embodiment, multipleconveyors are used and the speed of the conveyor controls the ratio ofmaterials sent to the size reduction device. The size reduction device(120) cuts and grinds the material to form uniform waste materialparticles not greater than one half inch in diameter and preferablybetween one half inch and one quarter inch in diameter.

A load metering device or similar device monitors the effort involved inthe shredding process and controls the intake of material. The machinecan support an optional electric generator and lights and an aircompressor, which are sometimes desirable features. The speed and torqueof the shredder is adjustable and can be changed to best deal withmaterial being fed into the machine. As an example, an exchangeable setof gears are used to alter speed/torque so as to address variable bulkdensity of waste materials.

The sized waste material leaves the shredder and is moved by an auger orconveying device (130) into soaking area. In the preferred embodiment,the soaking area has a rotating auger, which both stirs the wastematerial and moves it toward the next processing step. The soaking areahas an opening to allow the addition of the additive. As the material ismoved, it is the treated with the additive formulated for use with thatparticular waste material as per the earlier evaluation. The additive ismetered and falls into the sized material. Metering may be accomplishedusing a pellet meter or dosing unit (140), or may be tied to the augerspeed, or may be controlled by gate sizes, or may be tied to the speedof the conveyor(s) from the hopper(s). This entire operation of dosingand soaking may also be accomplished in the rotating auger listedearlier in this paragraph.

The material and additive(s) are blended at a temperature of at least130 degrees Fahrenheit, but preferably at least 135 degrees Fahrenheit,for at least one minute. As the material moves through the soaking area,it is monitored by devices to determine the moisture in material as ittravels through the soaking area via the auger. Nozzles (150), locatedalong the auger path, add water or blow air to alter moisture levels inmaterials. Heat is added, if necessary, by a heating element (160),preferably heating coils and recycled heat from the process.

The material may be passed by fixed magnets to remove unwanted ferrousmetal, the treated waste composition is then fed into a size reductiondevice, such as a hammer mill (170) for further mechanical blending fora more uniformed distribution of components in the composition andadditional size reduction until the size of the waste material particlesis not greater than one quarter inch. A sizing screen is used to be surelarger material does not move past the hammermill. The hammermill can beset by the machine operator to produce coarse or fine treated biomasscomposition.

The treated biomass composition is then fed toward the next step by adevice such as an auger (180). It falls into a press (190), such as arotary press or roller press, and is formed into pellets, briquettes,spheres or other desired shapes. In an alternative embodiment, thetreated biomass composition falls directly from the hammermill, which islocated above the press, and into the press under the control of gravityalone. Adjustments in the pressure applied by the press on the treatedbiomass composition in the formation of the solid fuel formations may beused to further adjust the BTU ratings and the bulk density. Theresulting solid formations may then be used directly as fuel.

An optional step of spraying the solid fuel formations with a coatingmay be used. A sprayer coats the solid fuel formations using a liquidstarch, gel, or other spray-able coatings. This protects the solid fuelformations during transportation and storage, preserves the shape of theformations, and reduces any release of undesired odors.

Although the additive composition may be blended with the waste materialat any point in the process prior to the shaping step, it is preferablyblended into the waste material particulates following the first sizingstep. The resulting biomass composition comprises between 3.2% to 56.00%by weight additive composition by weight and burns cleaner and morefully than conventional coal or blended biofuels as shown below.

The machine may have other features and enhancements that improve theoverall operation of the machine or enhance its value in a particularcircumstance. The machine operates at general atmospheric pressures anddoes not require the removal of oxygen or any gases. Removable accesspanels may be provided throughout the machine so as to allow easierrepair. A diversion flap may be provided to allow the removal ofunwanted materials without further processing. Nuts and bolts are usedwhen possible to allow easier access and maintenance. Sizing blades canbe replaced or removed and resharpened. Due to the nature of the serviceof the machine, many parts will need to be made of hardened steel orsimilar materials.

The machine is scalable. This would allow for a machine to be built tofit on a single truck-trailer or in a standard shipping container. Ifadditional capacity if desired, the machine could be scaled and built asa static device. In one embodiment, the machine is portable and scaledto fit on a single self-contained and moveable platform. This wouldallow movement of the machine without any disassembly.

The machine is a complete system so it is only necessary to handlegarbage or waste material once. So, garbage goes in and fuel comes out.The machine executes the process without additional human interaction.In the preferred embodiment, the machine is controlled via a singlecentral control panel.

Bioburn Results

Dry Ash Lbs Total Dry As-Rec Dry As-Rec Free Dry As-Rec Sodium SO2/MMBId1 Moisture Ash Ash BTU BTU BTU Sulfur Sulfur in Ash TU Coal Pak 8.1312.65 11.62 14142 10236 12756 0.69 0.63 1.30 1.24 Coal-Pak- 8.10 13.1712.10 14122 10221 12808 0.63 0.58 1.24 1.14 dup Coal/Corn 7.10 15.1414.07 8748 8128 10310 0.83 0.77 2.09 1.89 Stover (2) Pak Coal/Corn 7.0615.12 14.05 8758 8140 10318 0.84 0.78 2.03 1.93 Stover (2) Pak-dupCoal/Bio 8.66 19.75 18.04 8719 7964 10865 0.95 0.87 1.53 2.19 Blend 3Pak Coal/Bio 8.61 20.07 18.34 8672 7925 10850 0.96 0.88 1.50 2.21 Blend3 Pak-dup Corn 6.04 8.27 7.77 7573 7115 8256 0.07 0.06 0.76 0.18 StoverPak Corn 6.02 7.92 7.44 7524 7071 8171 0.05 0.05 0.80 0.14 StoverPak-dup

EXAMPLES

Waste material is selected and evaluated for moisture level, BTU levelsand emissions levels. An additive composition comprising sea salt andsoy flour is formulated based upon the desired BTU and emissions levels.

Still referring to FIG. 2, the waste material is then deposited into ahopper (100), which, using a conveyance device (110), feeds the wastematerial into a shredder (120), and waste materials pass through ashredder (120) to produce waste material particles having a diameter notgreater than one half inch. As an auger or conveyor (130) moves thesized waste material, the additive composition comprising the emissionsponge, BTU modifier and filler is then added by an additive meteringsystem (140) to the waste material particles until they are coated withthe additive composition.

The coated waste material particles are then transferred into an area orother receiving container for further treatment and the moisture contentand temperature of the mixture is determined. If the moisture content ofthe coated particulate matter is less than 12.0% by weight, water isadded by nozzles (150) until the moisture content of the waste materialparticles is preferably between 18.0 to 23% by weight. The wastematerial and additive composition are then allowed to soak attemperature and for a time sufficient to destroy most biological agents,typically at a temperature of at least 130 degrees Fahrenheit, butpreferably at least 135 degrees Fahrenheit, for at least one minute. Ifthe temperature of the mixture is less than 130 degrees F., thetemperature of the mixture is increased with an external heating deviceuntil the mixture reaches a temperature of at least 130 degreesFahrenheit and allowed to soak for at least one minute. This step killsbiological contaminants and accelerates breakdown of the mechanicalbonds within the waste materials.

In an alternative embodiment, the waste material particles are coatedwith a corresponding additive composition formulation following thefirst size reduction then transferred into a vat or similar container.The water content and temperature of the waste material particles ismeasured and adjusted so that the water content is at least 12% byweight and the temperature is at least 130 degrees Fahrenheit, butpreferably at least 135 degrees Fahrenheit.

If needed, the size of the waste material particles are then reduced asecond time by passing the coated particulates through a hammer mill(170) or similar size reduction device until the diameter of the wastematerial particulates is not greater than one half inch, but preferablynot greater than one quarter inch. The milled waste material particulateand additive composition mixture is then transferred to the press. Thepress then forms the material into desired solid fuel formations such aspellets, briquettes, and spheres. The resulting fuel formations may thenbe coated with starch for product stabilization.

The scope of the invention is not limited to the specific embodimentsdescribed herein. Rather, the claim should be looked to in order tojudge the full scope of the invention.

We claim:
 1. A method of producing a low emission biomass fuelcomposition from waste material comprising the steps of: a. feedingwaste material into a shredder; b. transferring the shredded wastematerial into a soaking area, wherein the soaking area comprises amoisture control device; c. measuring the moisture content of theshredded waste material contained within the soaking area with themoisture control device and adjusting the moisture content of thesoaking waste material to be within a predetermined moisture range; d.treating the shredded waste material within the soaking area, with anadditive comprising an emission sponge; e. transferring the treatedwaste material from the soaking area into a hammermill, and, f. formingsolid fuel structures from the treated waste material received from thehammermill.
 2. The method of claim 1, wherein the additive furthercomprises a BTU modifier.
 3. The method of claim 1, wherein emissionsponge comprises sea salt.
 4. The method of claim 1, wherein the soakingarea is a conveyor positioned between the shredder and a hammermill. 5.The method of claim 1, further comprising assessing the temperature ofthe waste material with a temperature monitoring device.
 6. The methodof claim 5, further comprising heating the treated material to atemperature of at least 130 degrees Fahrenheit for at least one minute.7. The method of claim 1, wherein the solid fuel structures are formedwith a press.
 8. The method of claim 7, wherein the press is a rollerpress.
 9. A solid fuel structure formed through the process comprisingthe steps of: a. feeding waste material into a shredder; b. transferringthe shredded waste material into a soaking area, wherein the soakingarea comprises a moisture control device; c. measuring the moisturecontent of the shredded waste material contained within the soaking areawith the moisture control device, and adjusting the moisture content ofthe soaking waste material to be within a predetermined moisture range;d. treating the shredded waste material within the soaking area, with anadditive comprising an emission sponge; e. transferring the treatedwaste material from the soaking area into a hammermill; and, f. formingsolid fuel structures from the treated waste material received from thehammermill.
 10. The solid fuel structure of claim 9, wherein theemission sponge is sea salt.